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I'm a student at the West-Flanders High School (HOWEST). I study
industrial product design and for one of our projects we have to make a flat packed product. The conditions imposed on our flat packed product are:

  • Finding a creative solution to create a volume out of a sheet material.
  • Apply the flat pack technique on products that aren't obvious to be flat packed.

This bikebag is made from simple materials such as wood and tablecloth. This is a prototype that has not been fully tested in real conditions.

Step 1: What Do You Need?

Tools:

  • Cutter knife
  • Clamps
  • Glue (two-component)
  • Screwdriver
  • Saw

Materials:

  • Waterproof cloth (fluorescent backpack cover, extra safe)
  • Plywood (5-10mm thick)
  • Tablecloth
  • 6 screws (10-15mm long)
  • 2 Springs of a clothespin
  • Pipe (handle)

Other:

  • Two 3D-printed clamps (2 parts)
  • 3D-printed protectionplate

(Print files)

Step 2: Cutting Up the Tablecloth

Cut the tablecloth with the cutter knife. Make sure the piece of cloth is long enough. The extra part is going to become the lid of the bag.

Step 3: Sawing the Plywood

There are several pieces of plywood. The total shape is the same as the shape cut out of the cloth.

The pieces:

  • 1 x 1cm
  • 1 x 2cm
  • 1 x 3cm
  • 2 x 5cm
  • 1 x 6cm
  • 1 x 7cm

These thicknesses are very important for a well functioning bag.

Step 4: Add Glue

Glue the outside-cloth between the plywood and the tablecloth. Both ends of the handle need to be glued between as wel. Use enough glue, but make sure the rest of the cloth does not get glued together. Also the sides of the plywood must be glue free!

2 pieces of plywood need to be as tight next to each other.

This part is the hardest part of the instructions, so take your time.

Step 5: Clamps and Protection Plate

The clamps are made of two 3D-printed parts that are assembled with the clothespins spring.

Bend the legs of the spring halfway as seen in the picture. Assemble the spring with part A (the part connected to the bag) and use twe screws to connect part A with the bag.

Then the other part is forced in the spring, this may take some patience.

The protection plate is screwed in at the bottom of the bag. The shape of the plate is the same as the first piece of plywood.

Step 6: Finishing

The last thing you need to do, is making a closing system. This can be made with click-systems from an old backpack, of a piece of strap.

Step 7: Final Result

And this is the final result.

An lightweight, flatpacked bikebag like no one else!

<p>Great flat pack design.</p>

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